U.S. patent application number 14/351834 was filed with the patent office on 2014-09-11 for continuous modular reactor.
The applicant listed for this patent is Council of Scientific & Industrial Research. Invention is credited to Amol Arvind Kulkarni, Vivek Vinayak Ranade.
Application Number | 20140255265 14/351834 |
Document ID | / |
Family ID | 47326222 |
Filed Date | 2014-09-11 |
United States Patent
Application |
20140255265 |
Kind Code |
A1 |
Kulkarni; Amol Arvind ; et
al. |
September 11, 2014 |
CONTINUOUS MODULAR REACTOR
Abstract
The present invention discloses a flow reactor composed of
plurality of modular/fluidic components that helps retain agility
and re-configurability of the continuous chemical processes with
improved processing ability. More specifically, disclosed herein is
a continuous flow reactor composed of varied permutations and
combinations of a plurality of modular/fluidic components for
chemical processing. The components are connected to each other
using connectors that facilitate the connection of either with two
or more, similar or different components.
Inventors: |
Kulkarni; Amol Arvind;
(Pune, IN) ; Ranade; Vivek Vinayak; (Pune,
IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Council of Scientific & Industrial Research |
New Delhi |
|
IN |
|
|
Family ID: |
47326222 |
Appl. No.: |
14/351834 |
Filed: |
October 15, 2012 |
PCT Filed: |
October 15, 2012 |
PCT NO: |
PCT/IB2012/002046 |
371 Date: |
April 14, 2014 |
Current U.S.
Class: |
422/211 |
Current CPC
Class: |
B01J 19/242 20130101;
B01J 2219/0002 20130101; B01J 19/243 20130101; B01J 2219/24
20130101; B01J 2219/1944 20130101; B01J 2219/00033 20130101 |
Class at
Publication: |
422/211 |
International
Class: |
B01J 19/24 20060101
B01J019/24 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 14, 2011 |
IN |
2957/DEL/2011 |
Claims
1. A flow reactor assembly that helps retain agility and
re-configurability of a continuous chemical process with improved
processing ability comprising a tubular reactor consisting of
metallic or non-metallic fluidic/modular components that are
arranged together in varied numbers and arrangement having single
or multi feed inlets, in periodic or aperiodic sequences; using
connectors that facilitate connection with two or more similar or
different components comprising; a helical coil element with
similar or variable radii of curvature, pitch and diameter with
single point or multi point feed arrangement, a flow disrupter
comprising a cross-sectional internal flow area shape selected from
the group consisting of cylindrical and polygonal, or a polyhedral
cavity with or without spatial variation in the internal flow area
and with suitable input and output connectable ports with the
helical coil elements; and/or a vortex diode comprising metallic or
non-metallic, single or multiple tangential ports of the diode as
inlet and an axial port as outlet and having connectable ports with
the helical coil elements; wherein said metallic or non-metallic
fluidic/modular components optionally comprise an internal flow
divider configured to achieve a desired residence time, to reduce
axial dispersion, and to enhance intensity of local mixing and
chemical reaction in the tubular reactor.
2. The flow reactor according to claim 1, wherein each of the
metallic or non-metallic fluidic/modular components further
comprise multiple metallic and non-metallic fluidic elements having
respective inlet and outlet ports.
3. The flow reactor according to claim 1, wherein the internal flow
area of the flow disruptor comprises respective inlet and outlet
ports; longitudinal variation in the open flow area, and a
plurality of metallic and non-metallic components in different
possible sequences.
4. The flow reactor according to claim 1, wherein the helical coil
element is in combination with other coil elements of different
coil diameter, wherein a smaller coil is held inside or outside the
volume occupied by a larger one with identical or non-identical
axis of symmetry for the individual coils.
5. The flow reactor according to claim 1, wherein a periodic and
aperiodic sequence of helical coil elements of identical curvature
and similar tube diameters are connected with non-cylindrical
segments comprising single point as well as multi point feeding
systems.
6. The flow reactor according to claim 1, wherein a periodic and
aperiodic sequence of helical coil elements of similar radii of
curvature with endpoints are attached to another coil having a
different radius of curvature and similar and a different tube
diameter and pitch.
7. The flow reactor according to claim 1, wherein a periodic and
aperiodic sequence of helical coil elements having similar radius
of curvature is connected with vortex diodes in a single point and
multi point feed arrangement.
8. The flow reactor according to claim 1, wherein a periodic and
aperiodic sequence of helical coil elements having similar radius
of curvature is connected with the vortex diode and the flow
disruptor in a single point and multi point feed arrangement.
9. The flow reactor according to claim 1, wherein the individual
metallic or non-metallic fluidic/modular components can have
identical or different axis of symmetry.
10-16. (canceled)
17. The flow reactor assembly of claim 1, wherein the flow
disruptor comprises a triangular, square or pentagonal
cross-sectional internal flow area shape.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a flow reactor composed of
plurality of fluidic components which helps retain agility and
re-configurability of the continuous chemical processes with
improved processing ability. More specifically, the invention
relates to a continuous reactor composed of varied permutations and
combinations of a plurality of modular elements for chemical
processing. The components are connected to each other using
connectors that facilitate the connection of either two or more,
similar or different components.
BACKGROUND OF THE INVENTION
[0002] Continuous reactors are perceived to be inflexible and less
agile in process modifications. Many multi-product manufacturing
therefore prefer batch processing. Batch processing plants are
typically arranged to operate in a batch mode with necessary
requirement of additional large batch tanks. Product quality in
batch processing may vary from batch to batch when compared to the
same process being carried out in a continuous operation.
Furthermore, the proportional increase in operating and maintenance
costs combined with the other shortcomings of batch processing
indicate the need for a more flexible and efficient
alternative.
[0003] Continuous flow reactor is being used over decades. However
the nature of the reactor has largely been like a simple tubular
reactor with either straight (U.S. Pat. No. 7,018,591,
US20030055300), tubes connected using 180.degree. bends (U.S. Pat.
No. 5,779,994, U.S. Pat. No. 3,773,470, U.S. Pat. No. 3,148,037),
the helical, lamellar or spiral configuration. A few configurations
with inserts have also been used (US20100040190). The purpose of
using these configurations was either to achieve the desired
residence time and/or to achieve the desired residence time with
reduced axial dispersion by using the geometrical variations to
perturb the flow to enhance local mixing. However these
configurations do not bring out a significant impact on the
enhancement of reactor performance.
[0004] There exists a need for an efficient system for carrying out
processes in a simple, quick and reconfigurable manner.
OBJECT OF THE INVENTION
[0005] Therefore an object of the invention is to provide a modular
and efficient system for carrying out processes in a simple, quick
and reconfigurable manner.
SUMMARY OF THE INVENTION
[0006] In accordance with the object, the present invention
provides novel modular reactor design that helps retain agility and
re-configurability of the continuous processes with better
processing ability via intensification of mixing and reaction.
[0007] In an aspect, the present invention discloses flow reactor
assembly comprising a tubular reactor consisting of at least one
metallic or non-metallic fluidic/modular component selected from
helical coils, flow disrupter, vortex diode arranged in varied
permutations and combinations. The fluidic/modular components may
be arranged together in any numbers and any arrangement having
single or multi feed options, in periodic or aperiodic sequences.
Further, they are connected to each other using connectors that
facilitate the connection with two or more similar or different
components in periodic or aperiodic sequences.
[0008] In an aspect, the individual modular/fluidic components can
have identical or different axis of symmetry.
[0009] Accordingly, present invention provides a flow reactor
assembly that helps retain agility and re-configurability of the
continuous chemical processes with improved processing ability
comprising a tubular reactor consisting of at least one metallic or
non-metallic fluidic/modular components selected from the group of
helical coils [1], flow disrupters [2], vortex diodes [3]
optionally having internals flow divider, wherein, said
fluidic/modular components can be arranged together in varied
numbers and arrangement having single or multi feed inlets, in
periodic or aperiodic sequences; wherein said tubular reactor along
with plurality of metallic or non-metallic fluidic components
achieved the desired residence time, reduced axial dispersion,
enhanced the intensity of local mixing and chemical reaction.
[0010] In an embodiment, present invention provides a flow reactor
wherein each of the fluidic component further comprises multiple
metallic and non-metallic fluidic elements having respective inlet
and outlet ports.
[0011] In yet another embodiment, present invention provides a flow
reactor wherein the said fluidic components are connected to each
other using connectors that facilitate the connection with two or
more, similar or different components in periodic or aperiodic
sequences.
[0012] In yet another embodiment, present invention provides a flow
reactor wherein flow disrupter[2] comprises internals having
respective inlet and outlet ports; longitudinal variation in the
open flow area, plurality of metallic and non-metallic components
in different possible sequences.
[0013] In yet another embodiment, present invention provides a flow
reactor wherein said flow disruptor [2] have a shape selected from
cylindrical or polygonal such as triangular, square or pentagonal,
cross-sectional or a polyhedral cavity with or without spatial
variation in the internal flow area and with suitable input and
output connectable ports with the helical coil elements.
[0014] In yet another embodiment, present invention provides a flow
reactor wherein vortex diode [3] optionally with internals
comprising metallic or non-metallic, single or multiple tangential
ports of the diode as inlet and an axial port as outlet and having
connectable ports with the helical coil elements.
[0015] In yet another embodiment, present invention provides a flow
reactor wherein the helical coils [1]in the reactor have variable
radii of curvature, pitch and diameter connected to each other
either in the same or different axis of symmetry for different
coils with single or multiple inlets for the assembly.
[0016] In yet another embodiment, present invention provides a flow
reactor wherein the helical coils [1] are in combination with
different coil diameter, wherein the smaller coil is held inside or
outside the volume occupied by the larger one with identical or
non-identical axis of symmetry for the individual coils.
[0017] In yet another embodiment, present invention provides a flow
reactor wherein a periodic and aperiodic sequence of coils of
identical curvature and similar tube diameter are connected with
non-cylindrical segments with single point as well as multi point
feeding system.
[0018] In yet another embodiment, present invention provides a flow
reactor wherein a periodic and aperiodic sequence of coils of
similar radii of curvature with endpoints attached to another coil
having different radius of curvature and similar and different tube
diameter and pitch.
[0019] In yet another embodiment, present invention provides a flow
reactor wherein a periodic and aperiodic sequence of helical coils
[1] having different radius of curvature and similar and different
tube diameter with single point or multi point feed.
[0020] In yet another embodiment, present invention provides a flow
reactor wherein a periodic and aperiodic sequence of helical coils
[1] having similar or different radius of curvature and similar or
different pitch and similar and different tube diameter at 180
degrees.
[0021] In yet another embodiment, present invention provides a flow
reactor wherein a periodic and aperiodic sequence of helical coils
[1] having similar radius of curvature is connected with vortex
diodes in a single point and multi point feed arrangement.
[0022] In yet another embodiment, present invention provides a flow
reactor wherein a periodic and aperiodic sequence of helical coils
[1] having similar radius of curvature is connected with vortex
diode and flow disruptor in a single point and multi point feed
arrangement.
[0023] In yet another embodiment, present invention provides a flow
reactor wherein individual modular/fluidic components can have
identical or different axis of symmetry.
[0024] In yet another embodiment, present invention provides a flow
reactor assembly that helps retain agility and re-configurability
of the continuous chemical processes with improved processing
ability comprising a tubular reactor consisting of at least one
metallic or non-metallic fluidic/modular components selected from
the group of helical coils [1], flow disrupters [2], vortex diodes
[3] optionally having internals, wherein, said fluidic/modular
components can be arranged together in varied numbers and
arrangement having single or multi feed inlets, in periodic or
aperiodic sequences;
[0025] wherein, each of the fluidic component further comprises
multiple metallic and non-metallic fluidic elements having
respective inlet and outlet ports; wherein, the said fluidic
components are connected to each other using connectors that
facilitate the connection with two or more, similar or different
components in periodic or aperiodic sequences.
BRIEF DESCRIPTION OF DRAWINGS
[0026] FIG. 1: illustrates a helical coil.
[0027] FIG. 2: illustrates various forms of flow disruptors.
[0028] FIG. 3: illustrates various forms of vortex diodes.
[0029] FIG. 4: illustrates a sequence of coils with identical
curvature with joining segments.
[0030] FIGS. 5 & 6: illustrate a sequence of coils with
non-similar radii of curvatures with end points attached to coils
having similar or non-similar radius.
[0031] FIG. 7: illustrates periodic and aperiodic sequence of coils
of different radius of curvature of similar or different tube
diameter having single or multi feed points.
[0032] FIG. 8: illustrates periodic and a periodic sequence of
coils of different tube diameter at 180 degrees.
[0033] FIG. 9: illustrates periodic and aperiodic sequence of coils
of different tube diameters.
[0034] FIG. 10: illustrates sequence of coils connected via vortex
diode.
[0035] FIG. 11: illustrates sequence of coils connected to vortex
diodes and flow disrupters having single or multi feed points.
DETAILED DESCRIPTION OF FIGURES
[0036] Component [201] includes a combination of two segments [212]
having same end size as that of a helical coil or other flow
disruptor elements [2] or a vortex diode [3] between which another
straight segment [210] is sandwiched having either higher or lower
flow area [211] straight flow paths with varying flow area and
their combinations [213, 214].
[0037] In another embodiment of the flow disruptor [2], the element
[210] can have a flow area comprising of two converging sections
[301] with the convergent ends either attached directly [302] or
through a spacing [303] or the flow area can have the form of two
diverging sections attached to each other at the enlarged area
[203] with smaller sections connected to the connecting element
[212].
[0038] In another embodiment of the flow disruptor [2], the element
[210] can have a flow area comprising of two converging sections
[301] with the convergent ends either attached directly [302] or
through a spacing [303] or the converging end of one converging
section is connected to the larger section of the subsequent
converging segment [204] or the spacing in the embodiment [303] is
extended to the wall [501] and connected [205] to another helical
coil [1] or the flow area can have the form of two diverging
sections attached to each other at the enlarged area through a
spacer [203] or directly [206] the with straight flow segments of
the connecting element [212].
[0039] In another embodiment of the flow disruptor [2], the element
[207] can have a step reduction [701] in the flow area [207] or a
sequence of converging segments [208A] of [204] or [209] of [206]
or the [208A] such that every single converging segment having an
internal flow divider [802] either in conical or cylindrical [803]
shape connecting to the straight flow segments of the connecting
element [212].
[0040] In another embodiment of the flow disruptor [2], the element
[210] can have a single [211] or multiple [210] cylindrical
obstacles having circular cross-section having the axis of symmetry
aligned with the connecting element [212] or not aligned [213] with
the connecting element [212]. The flow area of the cylindrical
inserts may or may not be equal to the flow area of the connecting
element [212].
[0041] In another embodiment of the flow disruptor [2], the element
[210] can be a helical screw [121] with constant pitch with the
threads having bores. The presence of screw helps to induce a
tangential motion inside the flow disruptor [2] while the bores in
the screw help achieve local mixing.
[0042] A vortex diode [3] is a fluidic element [801] having a
chamber [806], a tangential inlet [804] and an axial outlet [805].
The element [801] can be connected to the helical coil [1] through
its tangential inlet [804] and the axial outlet [805]. The
embodiment can have two [802] or four [803] tangential inlets
attached to the chamber [806] and one axial outlet [805]. The fluid
entering through the tangential inlets [804] undergoes a vortex
formation thereby enhancing mixing in the chamber [806] and leaves
the embodiment [8] through the axial outlet [805]
DETAILED DESCRIPTION OF INVENTION
[0043] Continuous tubular reactors usually have relatively higher
heat transfer area than the batch reactors of same volume. This
gives an advantage of better heat transfer properties thereby
helping to carry out the reactions at relatively higher rates
either by increasing the reactor temperature or by using higher
concentrations of the reactants. The extent of reactions in a
continuous tubular reactor can be manipulated by controlling the
residence time. With re-configurability, agility and flexibility of
manufacturing, the present invention discloses novel construction
of continuous flow reactors with enhanced modularity provided by
modular/fluidic components that can be arranged in various
permutations and combinations.
[0044] Accordingly, the present invention provides a continuous
flow reactor assembly which comprises of of at least one metallic
or non-metallic viz. glass, polymer, ceramic, composites, etc.
fluidic components. The components are connected to each other
using connectors that facilitate the connection either with two or
more similar or different components The individual components can
have identical or different axis of symmetry
[0045] The continuous flow reactor of the present invention helps
retain agility and re-configurability of the continuous processes
and also facilitates in achieving desired residence time, reducing
axial dispersion and enhancing mixing and reaction. The
modular/fluidic components can be chosen from a variety of helical
coils, flow disrupters and vortex diodes.
[0046] In a preferred embodiment, the present invention relates to
a flow reactor assembly that helps retain agility and
re-configurability of the continuous chemical processes with
improved processing ability comprising a tubular reactor consisting
of at least one metallic or non-metallic fluidic/modular components
selected from the group of helical coils [1], flow disrupters [2],
vortex diodes [3] optionally having internals, wherein, said
fluidic/modular components can be arranged together in varied
numbers and arrangement having single or multi feed inlets, in
periodic or aperiodic sequences; wherein, each of the fluidic
component further comprises multiple metallic and non-metallic
fluidic elements having respective inlet and outlet ports; wherein,
the said fluidic components are connected to each other using
connectors that facilitate the connection with two or more similar
or different components in periodic or aperiodic sequences;
[0047] wherein, said tubular reactor along with said plurality of
metallic or non-metallic fluidic components achieved the desired
residence time, reduced axial dispersion, enhanced the intensity of
local mixing and chemical reaction.
[0048] The fluidic components of the reactor are comprised of
individual parts that are referred to as `fluidic elements`.
[0049] The individual modular/fluidic components can have identical
or different axis of symmetry.
[0050] The tubular reactor in the present invention can be of
varied geometries consisting of single or multiple type of metallic
or non-metallic fluidic/modular components selected from the group
of helical coils [1], flow disrupters [2], vortex diodes [3]
optionally having internals.
[0051] In an embodiment [100], the present invention discloses a
plurality of fluidic/modular components arranged in varied
permutations and combinations selected from a variety of helical
coils [1], flow disrupters [2] and vortex diodes [3]. These may be
arranged together in any numbers and any arrangement having single
or multi feed options, in periodic or aperiodic sequences.
[0052] A simple helical coil is known to generate secondary flows
due to imbalance of forces acting on the fluid. While the secondary
flows, to some extent, help achieve better mixing, they also yield
more of a plug flow nature if the coils are very long and have
large radius of curvature. Hence it is necessary to incorporate
spatial variations in the nature of flow so that periodic or
aperiodic variations in the flow would help reduce the axial
dispersion and achieve rapid mixing. With the easy methods of
connecting the components, it yields a relatively flexible approach
to create such combinations to achieve the desired extent of mixing
in a simple manner.
[0053] Accordingly, as illustrated in FIG. 1, a helical coil [1]
made of tubes having specific constant radius, radius of curvature,
pitch and orientation that may be used in combination with helical
coils with identical coil diameter in having the pitch
(T[101]/T[102].about.0.1-10) with the smaller coil held inside or
outside the volume occupied by the larger one either with identical
[103, 106] or non-identical [104, 105, 107] axis of symmetry for
the individual coils. The end connections are designed in such a
way that they realize modularity in connecting the unit with other
modules.
[0054] The helical coils may be used either standalone or in
combination with flow disruptors and/or vortex diode and for with
combinations of helical coils of different tube radius, radius of
curvature, pitch and orientation. A stand-alone helical coil
typically has the problem of axial dispersion, which can be
overcome by inserting either a flow disruptor [2] or a vortex diode
[3]. A flow disruptor [2] would change the nature of flow in the
helical coil without changing the flow direction while a vortex
diode [3] would achieve the same by forcing the fluid to undergo a
vortex formation, both of which reduce the effects of axial
dispersion.
[0055] As illustrated in FIG. 2, a flow disruptor [2] may be a
cylindrical or polygonal (triangular, square or pentagonal)
cross-sectional or a polyhedral cavity with or without spatial
variation in the internal flow area [201-213] and with suitable
input and output connectable ports with the helical coil [1]
elements.
[0056] The flow disruptor [2] may have internals [802] to promote
mixing and dispersion. The internals rest on a porous support [803]
that reduces the local flow area in a range of (5%-30%) thereby
enhancing possible circulation zones. The end connections are
designed in such a way that they realize modularity in connecting
the unit with other modules.
[0057] As illustrated in FIG. 3, a vortex diode, that can be of any
size with aspect ratio between 3 and 7, with aspect ratio defined
as the ratio of diameter of the chamber to its height, is an
apparatus only used with tangential port as inlet and the axial
port as outlet. The vortex diode has a high resistance to flow in
one direction and a low resistance to flow in the other. It may be
used as leaky non return valve in applications, where it is
desirable to avoid valves with moving parts. The module may have
one or more tangential inlets. The module may also have internals
to promote the vortex strength. The vortex diode generates
cavitation conditions under certain inlet flow rate range when
fluid enters through the tangential inlet. The diodes help in
enhancing the reaction rates for the case of reacting flows. They
also help in generating secondary oxidizing agents due to cavity
break-up. The cavitation helps enhance the local temperature and
pressure inside the diode leading to enhanced reaction rates. FIG.
3 (A) illustrates a 3D image of a vortex diode while 3(B) and 3(C)
depict variants with multiple tangential inlet/outlet ports. FIG.
3(D) illustrates chambers with conical inserts having different
base diameter and height.
[0058] In an embodiment, the present invention disclose flow
reactor wherein the fluidic/modular components selected from
helical coils [1], flow disruptors [2] and vortex diodes [3] in the
tubular reactor may be in various combinations and are illustrated
in FIGS. 4, 5, 6, 7, 8, 9 and 10. The sequence as well as the
number of every module can vary depending upon the application.
[0059] In an embodiment, a periodic and aperiodic sequence of coils
of identical curvature and similar tube diameter connected with
non-cylindrical segments with single point as well as multi point
feeding system is disclosed as illustrated in FIG. 4.
[0060] In another embodiment, a periodic and aperiodic sequence of
coils of similar radii of curvature with endpoints attached to
another coil having different radius of curvature and similar and
different tube diameter and pitch as illustrated in FIGS. 5 and 6.
In yet another embodiment, a periodic and aperiodic sequence of
coils having different radius of curvature and similar and
different tube diameter with single point or multi point feed as
shown in FIG. 7. FIG. 8 disclose a periodic and aperiodic sequence
of coils having similar or different radius of curvature and
similar or different pitch and similar and different tube diameter
at 180 degrees.
[0061] In another embodiment, FIG. 9 illustrates a periodic and
aperiodic sequence of different tube diameter having identical
input and output port connections.
[0062] In yet another embodiment, a periodic and aperiodic sequence
of coils having similar radius of curvature connected with vortex
diodes in a single point feed arrangement and repetition of such an
arrangement in plurality as shown in FIG. 10.
[0063] FIG. 11 illustrates a periodic and aperiodic sequence of
coils having similar radius of curvature connected with vortex
diodes and flow disruptors in a single point and multi point feed
arrangement.
ADVANTAGES OF THE INVENTION
[0064] The flow reactor comprising of tubular reactor consisting of
metallic and non-metallic fluidic components selected from helical
coils, flow disrupters and vortex diode of the instant invention
arranged in varied combinations used in chemical processes result
in providing improved processing ability by achieving desired
residence time, reducing axial dispersion and enhancing the
intensity of local mixing. The fluidic components help to attain
agility and re-configurability of the continuous chemical processes
thereof.
* * * * *